Influence of Cutting Parameters on Surface Roughness for Wet and Dry Turning Process
Muhammad Yusuf
a, Khairol Anuar
b, Napsiah Ismail
cand Shamsuddin Sulaiman
dDepartment of Mechanical and Manufacturing Engineering Universiti Putra Malaysia 43400 Serdang, Selangor D.E. Malaysia
a[email protected], b[email protected], c[email protected],
Keywords: turning, surface roughness, parameters process, design of experiment
Abstract. This paper presents a study of the quality of a surface roughness model for mild steel with coated carbide cutting tool on turning process. The experiments were carried out under wet and dry cutting conditions. The model is developed based on cutting speed, feed and depth of cut as the parameters of cutting process. This research applies the fractional factorial design of experiment approach to studied the influence of cutting parameters on surface roughness. The measured results were collected and analyzed using commercial software package called Minitab. Analysis of variances is used to examine the influence of turning factors and factor interactions on surface roughness. The result indicated that, there are inherent differences in surface roughness between wet and dry cutting process with the same parameters process model. Analysis of variance was found that feed parameter is the most significant cutting parameter, which influences the surface roughness. The most significant interactions were found between cutting speed and feed parameters for dry turning process. Therefore is a significant effect of using combination of the fluid for cooling the cutting operation.
Introduction
Turning is the primary operation in most of the production processes in the industry. The starting material is generally a workpiece generated by other processes such as casting, forging, extrusion, or drawing.
In turning operation, the quality of surface roughness is an important requirement for many turned workpieces. Thus, the evaluation of machine tool and the choice of optimized cutting parameters becomes very important to control the required surface quality. The quality of machined component refers to studies have been reported recently, the final surface roughness obtained during turning operation may be considered as the sum of two independent effects [2,4]:
• ideal surface roughness, the result of the tool geometry and the feed rate, and
• natural surface roughness, the result of the irregularities in the cutting operation.
The factors contributing to natural surface roughness is the productivity of machine tools and mechanical parts. The occurrence of chatter or vibrations and inaccuracies parts movements of the machine tool can be affect on the surface quality.
Although many factors affect the surface conditions of a machined component, optimize of cutting condition is extremely important task to determine surface quality of manufactured parts.
Hence, surface roughness constitutes one of the most critical constraints for the selection of machine tools and cutting parameters in process planning. Majority of machining operations require the cooling and lubricating action of cutting fluids. But, due to ecological and human health problems, manufacturing industry are now being forced to implement strategies to reduce the amount of cutting fluids used in their production line. New approaches for elimination of cutting fluids application in machining processes have been examined and dry machining was presented as the solution.
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Experiment Setup
The material used for experiment is mild steel of hardness 180 HB. The workpiece received in the form of 38 mm diameter long bar and cut to 150 mm length, it is machined under dry and wet cutting condition. The machine used for turning operation is Harrison conventional lathe machine, maximum spindle speed achievable on this machine is 2200 rpm and spindle power 5.5 KW. The Taegutec TNMG 160408 MT TT5100 cutting tool insert coated carbide was used in the experimental with Mitsubishi tool holder MTJNR. The surface roughness was measured using Mahr Surftes. Design of experiment methodology used to determine the effects of cutting parameters on surface roughness in the turning. The factors and factorial levels are summarized in Table 1.
Experiment Result and Discussion
The present experiment results for assessment of surface roughness which was influenced by cutting speed, feed rate, and depth of cut parameters with dry and wet cutting condition according to 23 full factorial design as given in Table 2. Based on the results, the surface roughness in wet and dry turning was obtained in the range of 1.04 µm to 3.36 µm and 1.91 µm to 2.65 µm. The minimum values are the good quality of surface roughness, it has obtained during wet and dry turning process with the parameters model (v = 88 mm/min, f = 0.05 mm/rev, ap = 0.25 mm) and (v
= 129 mm/min, f = 0.05 mm/rev, ap = 0.5 mm). The comparison of the percentage difference in surface roughness between wet and dry process are illustrated in Fig. 1. The highest difference (45.8
%) occurred on the test no. 2 and lowest (9.5 %) on the test no. 7.
Table 1. Factors and factor levels Level
Factors Cutting speed v (m/min)
Feed f (mm/rev)
Depth of cut ap (mm)
Low (-1) 88 0.05 0.25
High (+1) 129 0.09 0.5
Table 2. Detail of experiment and results of wet and dry turning Cutting parameters Surface roughness (wet)
Ra (µm)
Surface roughness (dry) Ra (µm)
Test
No. v f ap Observed
Response
Average Respons
e
Observed Response
Average Respons
e
1 ─1 ─1 ─1 1.10 1.14 1.12 1.90 1.92 1.91
2 ─1 ─1 +1 1.02 1.06 1.04 1.87 1.97 1.92
3 ─1 +1 ─1 2.95 3.10 3.03 2.40 2.63 2.52
4 ─1 +1 +1 3.22 3.50 3.36 2.43 2.58 2.51
5 +1 +1 +1 2.77 3.16 2.97 2.53 2.77 2.65
6 +1 +1 ─1 2.35 3.77 3.06 2.58 2.67 2.63
7 +1 ─1 ─1 1.22 2.02 1.62 1.68 1.90 1.79
8 +1 ─1 +1 1.18 1.34 1.26 1.44 1.78 1.61
Fig. 1. The differences plots of surface roughness
Furthermore, the results were analyzed in the form of analysis of variance (ANOVA) in Minitab software. Its purpose is to determine which factors and factor interactions are statistically significant in affecting the surface roughness. Based on a 95% confidence interval, cutting speed, feed and depth of cut parameters have a statistically significant influence on surface roughness, since their p- values are smaller than 5%. Table 3 shows ANOVA for surface roughness in wet and dry turning processes. From the calculations can be inferred that feed has more influence on surface roughness in wet and dry turning processes, because their p-value are smaller than 0.05. In addition, the following two-factor the interactions of v-f parameters (cutting speed, feed) in dry turning process produce a statistically significant influence on the surface roughness, because p-values is also smaller than 0.05.
Further analysis can be conducted with the aid of the main effects and interaction plots. Fig. 2 gives the main effect plot of cutting speed on surface roughness in wet and dry turning. The surface roughness in wet turning appears to increase with increase of cutting speed, while it decreased with increase of cutting speed in dry turning. The surface roughness is tended increase with increase of feed in wet and dry turning are shown in Fig. 3. Fig. 4 gives the main effect plot of depth of cut on surface roughness, the surface roughness in wet and dry turning has a tendency to reduce with increase of depth of cut.
Table 3. Analysis of variance for surface roughness
Source Wet Dry
DF SS MS F P DF SS MS F P
v 1 0.0324 0.0324 0.20 0.667 1 0.00766 0.00766 0.40 0.541 f 1 13.5792 13.5792 82.87 0.000 1 2.34856 2.34856 124.04 0.000 ap 1 0.0100 0.0100 0.06 0.810 1 0.00601 0.00601 0.32 0.587 v * f 1 0.2916 0.2916 1.78 0.215 1 0.11731 0.11731 6.20 0.034 v * ap 1 0.1260 0.1260 0.77 0.403 1 0.00601 0.00601 0.32 0.587 f * ap 1 0.1156 0.1156 0.71 0.423 1 0.00856 0.00856 0.45 0.518
Error 9 1.4747 0.1639 9 0.17041 0.01893
Total 15 15.6296 15 2.66449
In order to determine the interaction effects of cutting process parameters on Ra, the three- dimensional surface plots were generated considering two parameters at a time. These interaction effects are depicted in Fig. 5, 6 and 7. From these figures, it is observed that the interaction effects
Fig. 2. The main effect plots of cutting speed on surface roughness
Fig. 3. The main effect plots of feed on surface roughness
Fig. 4. The main effect plots of depth of cut on surface roughness
Fig. 5. Interaction effect of cutting speed and feed on surface roughness
Fig. 6. Interaction effect of cutting speed and depth of cut on surface roughness
Fig. 7. Interaction effect of feed and depth of cut on surface roughness Summary
In this paper, the influence of cutting process parameters on surface roughness for mild steel with coated carbide cutting tool during wet and dry turning process have been measured. Based on the results, it was found that cutting process parameters (cutting speed, feed and depth of cut) has influences on surface roughness in wet and dry cutting condition. The following conclusion can be drawn:
The minimum values of surface roughness are the good quality, it obtained during wet and dry turning process with the parameters model (v = 88 mm/min, f = 0.05 mm/rev, ap = 0.25 mm) and (v = 129 mm/min, f = 0.05 mm/rev, ap = 0.5 mm).
There are inherent differences in surface roughness between wet and dry cutting process with the same parameters of process, the highest difference (45.8%) occurred on the test no. 2 and lowest (9.5 %) on the test no. 7.
Muhammad Wildan Ilyas from the Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia Universiti Putra Malaysia for their assistance.
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Influence of Cutting Parameters on Surface Roughness for Wet and Dry Turning Process
doi:10.4028/www.scientific.net/KEM.471-472.233
